Trace charger [RE-wrenches]

[Chuck Heath, SunPower]

Client reported charger of a SW 4024 (v. 4.01) not working properly. Site 
visit confirmed this. Only charging source is a Kohler 12 RY generator, 
re-wired for 120 VAC (12 kW before altitude derating). Battery is type 
85-25 two-volt cells, 1270 AH @ 20 hr. discharge rate. System installed 
in 1998.

Symptoms: Trace sees AC-2 Good from Kohler, goes into Bulk charging for 
only 30-35 seconds, then drops out of Bulk and back to inverting for 10 
seconds until cycle repeats. Kohler voltage is a steady 117-118 VAC 
whether under load or not. Trace reports Kohler frequency as rock-solid 
60 cps.

After nearly 6 hours generator runtime, was able to raise battery voltage 
from 26.8 to 27.2 VDC - not nearly enough. At-rest battery voltage was 
24.9 VDC. Set Gen Amps AC (Menu #11) and Set Max Charge Amps AC (Menu 
#10) are both at 35 Amps AC. Lower values did not change results, nor did 
changing Set Float Voltage (27.1 VDC) to match Set Bulk Voltage setting 
(Menu #10) of 29.8 VDC.

Bryan at Trace Tech Support (<tracetech at traceengineering.com> and 
telephone extension 2203) recommended switching Kohler output from SW Gen 
Input to SW Grid Input, AC-1. 

Did that. Result was the same, except for causing a Generator Start error 
which shut down the Kohler in less than a minute from RY 7. Running the 
Kohler using its "Run" instead of the "Auto" switch position caused the 
same cycling of 30-35 sec. Bulk charging, 10 sec. of inverting, then back 
to Bulk charging. Ambient air temp was 68 upon arrival, 86 degrees F. by 
early afternoon. Trace internal fan worked just fine. 

All Trace menu settings were checked at least twice and found to be 
correct.
Did not try using the default menu settings.

Ideas?

Chuck Heath "Plugging into Sunshine since 1989"
Big Oak Flat CA
sunpwr at jps.net
209 962-7012 

- - - - - - -
To send a message to the list use: <RE-wrenches at topica.com>

To view an archive of previous messages go to: <http://www.topica.com/lists/RE-wrenches/

To unsubscribe send an email message to: <RE-wrenches-unsubscribe at topica.com>

To check out who the other RE-Wrench participants are, go to <http://www.mrsharkey.com/wrenches/>

Hosted by Home Power magazine: <http://www.homepower.com>

for info contact: <michael.welch at homepower.com>
___________________________________________________________
T O P I C A  The Email You Want. http://www.topica.com/t/16
Newsletters, Tips and Discussions on Your Favorite Topics